Processes for manufacture of a press jacket

ABSTRACT

Process for manufacturing a roll press jacket, wherein the roll press jacket includes a hollow cylindrical sleeve made of an castable elastomeric material containing at least one crystallization component, the sleeve has an interior cylindrical surface and an exterior cylindrical surface. The internal surface and the external surface have different hardness characteristics. The process includes using a cylindrical casting mold having an casting surface, the casting mold having a temperature which is maintained at a temperature colder than an elastomeric material being cast, casting a hollow cylindrical sleeve from the elastomeric material on the casting mold, the elastomeric material containing at least one crystallization component, providing the sleeve with an interior cylindrical surface and an exterior cylindrical surface, one of the internal or external surfaces being formed against the casting surface of the cylindrical casting mold, wherein the surface of the sleeve which is formed against the casting surface is harder than a surface which is not formed against the casting surface.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a divisional application of application Ser.No. 09/460,427, now U.S. Pat. No. 6,406,414 filed on Dec. 14, 1999, thedisclosure of which is expressly incorporated by reference herein in itsentirety. Additionally, this application claims priority under 35 U.S.C.§119 of German Patent Application No. 198 60 099.2, filed on Dec. 23,1998, the disclosure of which is expressly incorporated by referenceherein in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to a cylindrical press jacket made of a castableelastomeric material for use on a press device which treats materials inthe form of a web. The press device is particularly used for dewateringor smoothing a fibrous material web. The jacket will also havereinforcement threads and/or reinforcement fabric embedded in theelastomeric material and is made with the hardness of the material inthe area of the interior side being different from the exterior side ofthe press jacket. A process for manufacturing the press jacket is alsodisclosed.

2. Discussion of Background Information

Press jackets are generally known, for example, from DE-OS 196 54 194and DE-OS 196 54 751; in particular, which use reinforcement threads andcast the press jacket from a homogeneous material. They use relativelylarge distances between the reinforcement threads to facilitate theirmanufacture which allows the material to sufficient penetration thespaces formed between these distances.

The manufacturing the jacket in a single casting process also has theadvantages of being simpler to manufacturing and producing a jacket withimproved strength.

However, depending on the application, it may be necessary to make thejacket with different hardness characteristics between interior andexterior sides. For example, a harder exterior side has advantage withregard to improved abrasion resistance. This characteristic isespecially desired when the press jacket is to have grooves or blindholes for receiving the pressed-out water. In contrast, a harderinterior side allows for less oil absorption and improves the runningproperties of hydraulically supported press jackets.

SUMMARY OF THE INVENTION

The invention provides for a press jacket and a manufacturing process inwhich the press jacket has different hardness characteristics betweenits interior and exterior sides. Moreover, the jacket is made from anelastomeric material which contains at least one component which causesstronger crystallization in the area of the casting mold during castingon a relatively cold casting mold.

The jacket ideally cast against a mold which is colder than the jacketmaterial being cast. The surface formed against the colder moldgenerally experiences stronger crystallization, and the result is agenerally higher proportion of hard segments being formed on thissurface. Thus the surface which is formed against the mold will beharder than the other parts of the jacket.

The elastomer material may be, for example, polyurethane and madeinclude polymers or prepolymers, such as diphenylmethan—diisozyanate(MDI) with polyester, since they are appropriate as components forstrengthen crystallization. In addition, the elastomeric material shouldalso contain a cross-linker.

The differences in the hardness between the interior and exterior sidesshould be in the range of approximately 2 to 7 Shore A. For example, oneside may have a hardness in the range of approximately 92 to 96 shore A,while the other side has a hardness of approximately 94 to 98 shore A.However, each surface may also be as low as approximately 85 shore A isdesired.

By manipulating the manufacturing process, it is therefore possible toinfluence which side is to be made harder. Thus in order to manufacturea harder interior side, the elastomeric material is applied to theexterior side of a cylindrical casting mold, since a surface which isformed against a mold surface will be made harder. If it is desired tomake the exterior side harder, then the elastomeric material is appliedto the interior side of a hollow cylindrical casting mold, again since asurface which is formed against a mold surface will be made harder.Preferably the jacket is cast using conventional centrifugal orhot-casting techniques such as those discussed in U.S. Pat. No.5,766,421. Moreover, the particulars of such conventional molding areidentified in each of U.S. Pat. Nos. 5,118,391 and 5,134,010, which arefully incorporated by reference. These conventional techniques beingmodified by the use of a mold which is colder than the casting materialas described herein.

In either case the temperature of the casting mold should be controlledbetween approximately 10 and 100° C., and preferably betweenapproximately 20 and 80° C., colder than the temperature of theelastomeric material being cast. For it is this cold mold effect whichcauses a elastomer material formed against it to become harder.Preferably, the mold is preheated to the desired temperature. For thispurpose, a heavy steel mold is preferred since it can maintain thedesired temperature for a relatively long period of time.

Even more control over the formation of the various degrees of hardnessis improved by the use of reinforcement threads or the reinforcementfabric, because this acts as an insulating layer and therefore limitsthe temperature effect of the cold casting mold to the area between thecontact or forming surface and the reinforcement threads orreinforcement fabric. The reinforcing fibers made be those which areconventionally and can include polyester, polyamid, and/or aramid.

According to one aspect of the invention, there is provided acylindrical press jacket for treating a material web which includes ahollow cylindrical sleeve made of an castable elastomeric materialcontaining at least one crystallization component, wherein the sleevehas an interior cylindrical surface and an exterior cylindrical surface,and one of reinforcement threads and reinforcement fabric embedded inthe elastomeric material, such that the hardness of the elastomericmaterial in an area of the interior surface differs from a hardness ofthe exterior surface. The jacket may be made using a casting mold whichis colder than the elastomeric material being cast. The cold castingmold may be positioned against the interior surface so as to cause agreater crystallization to occur in on the interior surface relative tothe exterior surface. Alternatively, the cold casting mold may also bepositioned against the exterior surface so as to cause a greatercrystallization to occur in on the exterior surface relative to theinterior surface. Moreover, the jacket may be used for one of dewateringand smoothing a fibrous material web. The greater crystallization maycorrespond to greater hardness.

The invention also provides that the crystallization component includesa polymer. The polymer may be a prepolymer. The difference between thehardness of the interior surface and the exterior surface may be in arange of approximately 2 to 7 Shore A.

According to another aspect of the invention, there is provided aprocess for manufacturing a press jacket which includes using acylindrical casting mold having an exterior surface, setting atemperature of the cylindrical casting mold which is colder than anelastomeric material being cast, casting a hollow cylindrical sleevefrom the elastomeric material on the casting mold, such that theelastomeric material contains at least one crystallization component,embedding one of reinforcement threads and reinforcement fabric in theelastomeric material, providing the sleeve with an interior cylindricalsurface and an exterior cylindrical surface, such that the internalsurface is formed against the external surface of the cylindricalcasting mold, wherein the internal surface of the sleeve is harder thanthe external surface of the jacket.

According to still another aspect of the invention, there is provided aprocess for manufacturing a press jacket which includes providing acylindrical casting mold having a hollow internal surface, such that thecasting mold has a temperature which is colder than an elastomericmaterial being cast, casting a hollow cylindrical sleeve from theelastomeric material on the casting mold, such that the elastomericmaterial contains at least one crystallization component, embedding oneof reinforcement threads and reinforcement fabric in the elastomericmaterial, providing the sleeve with an interior cylindrical surface andan exterior cylindrical surface, such that the external surface isformed against the hollow internal surface of the hollow cylindricalcasting mold, wherein the external surface of the sleeve is harder thanthe external surface of the sleeve. The process may provide that themold temperature is between approximately 10 and 100° C. colder than atemperature of the elastomeric material being cast. Additionally, themold temperature may be between approximately 20 and 80° C. colder thana temperature of the elastomeric material being cast. Alternatively, themold temperature may be between approximately 10 and 100° C. colder thana temperature of the elastomeric material being cast. The moldtemperature may also ideally be between approximately 20 and 80° C.colder than a temperature of the elastomeric material being cast.

The invention also provides for a roll press jacket which includes ahollow cylindrical sleeve made of an castable elastomeric materialcontaining at least one crystallization component, such that the sleevehas an interior cylindrical surface and an exterior cylindrical surface,wherein the internal surface and the external surface have differenthardness characteristics. The jacket may further include one ofreinforcement threads and reinforcement fabric embedded in theelastomeric material. The one of reinforcement threads and reinforcementfabric may include one of polyester, polyamid, and aramid. The jacketmay be made using a casting mold which is colder than the elastomericmaterial being cast. Moreover, the interior side may have a hardness inthe range of approximately 92 to 96 shore A. Additionally, the interiorside may have a hardness in the range of approximately 94 to 98 shore A.The exterior side may have a hardness in the range of approximately 92to 96 shore A. The exterior side may also have a hardness in the rangeof approximately 94 to 98 shore A. Furthermore, the cold casting moldmay be positioned against the interior surface so as to cause a greatercrystallization to occur in on the interior surface relative to theexterior surface. The greater crystallization may correspond to greaterhardness. The cold casting mold may be positioned against the exteriorsurface so as to cause a greater crystallization to occur in on theexterior surface relative to the interior surface. The greatercrystallization may further correspond to greater hardness.

The jacket may be used for one of dewatering and smoothing a fibrousmaterial web. The crystallization component may include a polymer. Thepolymer may be a prepolymer. The prepolymer may include diphenylmethanor diisozyanate (MDI) with polyester. Moreover, the elastomer materialmay include polyurethane. The jacket may provide for difference betweenthe hardness of the interior surface and the exterior surface to be in arange of approximately 2 to 7 Shore A. The interior side may have ahardness in the range of approximately 92 to 96 shore A. The interiorside may also have a hardness in the range of approximately 94 to 98shore A. Furthermore, the exterior side may have a hardness in the rangeof approximately 92 to 96 shore A. The exterior side may also have ahardness in the range of approximately 94 to 98 shore A.

The invention also provides for a process for manufacturing a pressjacket which includes using a cylindrical casting mold having anexterior surface, setting a temperature of the cylindrical casting moldwhich is colder than an elastomeric material being cast, casting ahollow cylindrical sleeve from the elastomeric material on the castingmold, such that the elastomeric material containing at least onecrystallization component, providing the sleeve with an interiorcylindrical surface and an exterior cylindrical surface, such that theinternal surface is formed against the external surface of thecylindrical casting mold, wherein the internal surface of the sleeve isharder than the external surface of the sleeve. The method may alsoprovide for embedding one of reinforcement threads and reinforcementfabric in the elastomeric material. Moreover, the mold temperature maybe between approximately 10 and 100° C. colder than a temperature of theelastomeric material being cast. The mold temperature may also bebetween approximately 20 and 80° C. colder than a temperature of theelastomeric material being cast.

According to another aspect of the invention, there is provided aprocess for manufacturing a press jacket which includes using acylindrical casting mold having a hollow internal surface, setting atemperature of the cylindrical casting mold which is colder than anelastomeric material being cast, the temperature being maintained,casting a hollow cylindrical sleeve from the elastomeric material on thecasting mold, such that the elastomeric material contains at least onecrystallization component, providing the sleeve with an interiorcylindrical surface and an exterior cylindrical surface, such that theexternal surface is formed against the internal surface of thecylindrical casting mold, wherein the external surface of the sleeve isharder than the internal surface of the sleeve. The method may alsoinclude embedding one of, reinforcement threads and reinforcement fabricin the elastomeric material.

The process may provide that the mold temperature is betweenapproximately 10 and 100° C. colder than a temperature of theelastomeric material being cast. The mold temperature may also bebetween approximately 20 and 80° C. colder than a temperature of theelastomeric material being cast.

The invention also provides for a cylindrical press jacket for treatinga material web, which includes a hollow cylindrical sleeve made of ancastable elastomeric material containing a prepolymer, the sleeve havingan interior cylindrical surface and an exterior cylindrical surface, oneof reinforcement threads and reinforcement fabric embedded in theelastomeric material, wherein the jacket is made using a cylindricalcasting mold which is maintained at a temperature that is approximately20 to 80° C. colder than the elastomeric material being cast, such thata sleeve surface which is formed against the casting mold has a hardnessin the range of approximately 2 to 7 Shore A greater than a sleevesurface which does not contact the casting mold.

Moreover the invention also provides for a process for manufacturing apress jacket which includes using a cylindrical casting mold having acasting surface, setting a temperature of the cylindrical casting moldwhich is colder than an elastomeric material being cast, wherein themold has a temperature which is maintained at a temperatureapproximately 20 to 80° C. that is colder than an elastomeric materialbeing cast, casting a hollow cylindrical sleeve from the elastomericmaterial on the casting mold, wherein the elastomeric material containsa prepolymer, providing the sleeve with an interior cylindrical surfaceand an exterior cylindrical surface, with either one of the external andinternal surfaces being formed against the casting surface of thecylindrical casting mold, creating greater crystallization in the sleevesurface which contacts the cold mold surface, wherein the greatercrystallization corresponds to greater hardness in the sleeve surfacerelative to other portions of the elastomer material, such that thegreater hardness is in the range of approximately 2 to 7 Shore A.

Other exemplary embodiments and advantages of the present invention maybe ascertained by reviewing the present disclosure and the accompanyingdrawing.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is further described in the detailed descriptionwhich follows, in reference to the noted plurality of drawings by way ofnon-limiting examples of exemplary embodiments of the present invention,in which like reference numerals represent similar parts throughout theseveral views of the drawings, and wherein:

FIG. 1 shows a cross-section of a press jacket formed on a mold;

FIG. 2 shows the jacket formed on an interior surface of cylindricalcasting mold; and

FIG. 3 shows the jacket formed on an exterior surface of cylindricalcasting mold.

DETAILED DESCRIPTION OF THE PRESENT INVENTION

The particulars shown herein are by way of example and for purposes ofillustrative discussion of the embodiments of the present invention onlyand are presented in the cause of providing what is believed to be themost useful and readily understood description of the principles andconceptual aspects of the present invention. In this regard, no attemptis made to show structural details of the present invention in moredetail than is necessary for the fundamental understanding of thepresent invention, the description taken with the drawings makingapparent to those skilled in the art how the several forms of thepresent invention may be embodied in practice.

The invention is explained below in reference to an exemplaryembodiment. In the attached drawings, FIG. 1 shows a schematic partialsection through tubular press jacket 2 as well as cylindrical castingmold 6. Press jacket 2 is between approximately 5 and 6 mm thick, theinterior side is smooth, and the exterior side is usually provided withblind holes or grooves.

A castable elastomeric material 1, e.g., polyurethane, of press jacket 2is supplemented by a prepolymer, such as diphenylmethan—diisozyanate(MDI) with polyester, which causes stronger crystallization and a higherproportion of hard segments in the area of casting mold 6 during castingonto a colder casting mold 6.

Press jacket 2 contains reinforcement threads 3 running lengthwise andcrosswise, which are completely surrounded by elastomeric material 1.

Elastomeric material 1 is generally processed in the conventional mannerat temperatures between approximately 50 and 100° C., except that thetemperature of casting mold 6 is between approximately 20 and 80° C.less than the temperature of elastomeric material 1.

In one example shown in FIG. 2, press jacket 2 with a harder exteriorside 5 is manufactured. This is accomplished by applying elastomericmaterial 1 to interior side 7 of a cylindrical casting mold 6, e.g., ametal mold. However, it is noted that if the interior side 4 is to bemade harder, elastomeric material 1 is applied instead to exterior side8 of the same of cylindrical casting mold 6, as is shown in FIG. 3.Alternatively, different mold designs may be used to for casting eachside differently without departing from the scope and sprit of thepresent invention.

Reinforcement threads 3, e.g., include polyester, polyamid, and/oraramid fibers, may provide an insulating effect, in which the effect ofthe temperature of casting mold 6 is limited to an area between thethreads and the mold contact surface. Thus, only this area becomesharder, e.g., in the exemplary embodiment, the area of exterior side 5of press jacket 2. It is noted that mold 6 is very heavy, e.g., 15-20tons, which enables the temperature to remain substantially constantduring the casting process. In this respect, mold 6 can be preheated toa desired temperature, i.e., before the casting process, to a certaintemperature.

The result is that differences in hardness between interior side 4 andexterior side 5 of press jacket 2 can be produced ranging fromapproximately 2 to 7 Shore A. The differences in the hardness betweeninterior side 4 and exterior side 5 should be tailored to the particularneeds of web making process. For example, the hardness values of oneside may range from approximately 92 to 96 shore A, while the other sidemay have a hardness of approximately 94 to 98 shore A.

FIG. 2 shows in a very basic way how press jacket 2 is formed with aharder exterior side 5. Cylindrical casting mold 6 has interior side 7against which elastomer material 1 is applied. Elastomer material 1 isfed at increased temperature through line 11 and through a first castingnozzle 12, while cylindrical casting mold 6 is rotated about its centralaxis 10, in the direction indicated by arrow 9. Nozzle 12 may further beslid in a direction parallel to central axis 10 in order to graduallyproduce press jacket 2 in a continuous process.

FIG. 3 shows the same process as FIG. 2 except that elastomer materialis applied to exterior side 8 of cylindrical casting mold 6.

It is noted that the foregoing examples have been provided merely forthe purpose of explanation and are in no way to be construed as limitingof the present invention. While the present invention has been describedwith reference to an exemplary embodiment, it is understood that thewords which have been used herein are words of description andillustration, rather than words of limitation. Changes may be made,within the purview of the appended claims, as presently stated and asamended, without departing from the scope and spirit of the presentinvention in its aspects. Although the present invention has beendescribed herein with reference to particular means, materials andembodiments, the present invention is not intended to be limited to theparticulars disclosed herein; rather, the present invention extends toall functionally equivalent structures, methods and uses, such as arewithin the scope of the appended claims.

What is claimed:
 1. A process for manufacturing a press jacket in anapparatus that includes a cylindrical casting mold having a hollowinternal surface, said process comprising: setting a temperature of thecylindrical casting mold which is colder than an elastomeric materialbeing cast; casting a hollow cylindrical sleeve from the elastomericmaterial on the casting mold, the elastomeric material containing atleast one crystallization component, the hollow cylindrical sleeveincluding an external surface which is formed against the hollowinternal surface of the cylindrical casting mold; and embedding at leastone of reinforcement threads and reinforcement fabric in the elastomericmaterial, whereby said external surface of said hollow cylindricalsleeve is harder than an internal surface of said sleeve.
 2. The processof claim 1, wherein the cylindrical casting mold temperature is betweenapproximately 10 and 100° C. colder than a temperature of theelastomeric material being cast.
 3. The process of claim 2, wherein thecylindrical casting mold temperature is between approximately 20 and 80°C. colder than a temperature of the elastomeric material being cast. 4.A process for manufacturing a press jacket in an apparatus that includesa cylindrical casting mold having an exterior surface, said processcomprising: setting a temperature of the cylindrical casting mold whichis colder than an elastomeric material being cast; casting a hollowcylindrical sleeve from the elastomeric material on the casting mold,the elastomeric material containing at least one crystallizationcomponent, the hollow cylindrical sleeve including an internal surfacewhich is formed against the external surface of the cylindrical castingmold; and embedding at least one of reinforcement threads andreinforcement fabric in the elastomeric material; whereby the internalsurface of the hollow cylindrical sleeve is harder than an externalsurface of the hollow cylindrical sleeve.
 5. The process of claim 4,wherein the cylindrical casting mold temperature is betweenapproximately 10 and 100° C. colder than a temperature of theelastomeric material being cast.
 6. The process of claim 5, wherein thecylindrical casting mold temperature is between approximately 20 and 80°C. colder than a temperature of the elastomeric material being cast. 7.A process for manufacturing a press jacket in an apparatus that includesa cylindrical casting mold having an external surface, said processcomprising: setting a temperature of the cylindrical casting mold whichis colder than an elastomeric material being cast; and casting a hollowcylindrical sleeve from the elastomeric material on the casting mold,the elastomeric material containing at least one crystallizationcomponent, the hollow cylindrical sleeve including an internal surfacewhich is formed against the external surface of the cylindrical castingmold; wherein said internal surface of said hollow cylindrical sleeve isharder than an external surface of said hollow cylindrical sleeve. 8.The process of claim 7, further comprising: embedding at least one ofreinforcement threads and reinforcement fabric in the elastomericmaterial.
 9. The process of claim 7, further comprising: setting themold temperature between approximately 10 and 100° C. colder than atemperature of the elastomeric material being cast.
 10. The process ofclaim 9, further comprising: setting the mold temperature betweenapproximately 20 and 80° C. colder than a temperature of the elastomericmaterial being cast.
 11. A process for manufacturing a press jacket inan apparatus that includes a cylindrical casting mold having a hollowinternal surface, said process comprising: setting a temperature of thecylindrical casting mold which is colder than an elastomeric materialbeing cast; casting a hollow cylindrical sleeve from the elastomericmaterial on the cylindrical casting mold, the elastomeric materialcontaining at least one crystallization component, the hollowcylindrical sleeve including an external surface which is formed againstthe internal surface of the cylindrical casting mold, wherein saidexternal surface of said hollow cylindrical sleeve is harder than aninternal surface of said hollow cylindrical sleeve.
 12. The process ofclaim 11, further comprising: embedding at least one of reinforcementthreads and reinforcement fabric in said elastomeric material.
 13. Theprocess of claim 11, further comprising: setting the mold temperaturebetween approximately 10 and 100° C. colder than a temperature of theelastomeric material being cast.
 14. The process of claim 13, furthercomprising: setting the mold temperature between approximately 20 and80° C. colder than a temperature of the elastomeric material being cast.15. A process for manufacturing a press jacket in an apparatus thatincludes a cylindrical casting mold having at least one casting surface,said process comprising: setting a temperature of the cylindricalcasting mold which is colder than an elastomeric material being cast,said cylindrical casting mold having a temperature which is maintainedat a temperature approximately 20 to 80° C. colder than the elastomericmaterial being cast; casting a hollow cylindrical sleeve from theelastomeric material on the cylindrical casting mold, the elastomericmaterial containing a prepolymer, such that the hollow cylindricalsleeve is provided with an interior cylindrical surface and an exteriorcylindrical surface, wherein one of said external surface and saidinternal surface is formed against said casting surface; creatinggreater crystallization in a sleeve surface which contacts said castingsurface; wherein the greater crystallization corresponds to greaterhardness in said sleeve surface relative to other portions of theelastomer material, the greater hardness being in the range ofapproximately 2 to 7 Shore A.